Product Data Sheet PDS 103-1000.A01 December 2005 Model 1000 Process Gas Chromatograph Emerson Process Management offers a complete line of gas chromatographs specifically designed for process applications. The Model 1000 Process Gas Chromatograph combines the proven analytical components of the Model 500 and Model 700 with the larger oven capacity of a traditional air-bath oven design. The result is maximum analyzer reliability and analytical flexibility in one package. FEATURES Traditional air-bath oven design for maximum application fl exibility Fully compatible with modern Ethernet networks and DCS communication Diaphragm-based 6-port chromatograph valves Oven capacity for up to six chromatograph valves and two detectors Choice of Thermal Conductivity, Flame Ionization or Flame Photometric Detectors Thermal Conductivity Detector (TCD) sensitive down to very low parts-permillion levels Last chromatogram for each sample and calibration stream stored in process gas chromatograph Archives up to 254 item averages, more than 3 months of standard runs and calculations APPLICATIONS The Model 1000 is designed for a variety of refi ning, petrochemical, food and beverage, pharmaceutical, power and environmental applications where selected components in gaseous or liquid streams must be precisely monitored on a continuous basis. Refineries Catalytic reformer Isomerization unit Aromatics unit Petrochemical Ethylene plants Polymer plants Acrylonitrile plants Gas Processing NGL, GTL and LNG plants Cryogenic gas plants Power Generation Power generation plants Gas turbine control Environmental Monitoring Ambient air monitoring HR-VOCs in fl ares and cooling towers The Rosemount Analytical Process Gas Chromatograph Difference Broad application scope with single- or dual- detector capability High-sensitivity thermal conductivity detectors can often replace more complex detectors Easy-to-use MON2000 software for advanced diagnostics and simplifi ed troubleshooting; simply the best in the industry Rosemount Analytical diaphragm valves offer a lifetime warranty Visit our website at www.raihome.com On-line ordering available.
Gas Chromatograph Valves The chromatograph valves used in Rosemount Analytical Process Gas Chromatographs are unique to the on-line gas chromatograph market. Using a design originally developed by NASA, the valve offers greatly extended operating life. Emerson Process Management is currently the only on-line gas chromatograph supplier to offer a lifetime warranty on their Rosemount Analytical chromatograph valves! Simple mechanical design Sample does not come in contact with internal moving parts More than 5 million operations per valve Lifetime warranty Rotary liquid injection valves also available for special applications The reason for the exceptional durability of the valve is its unique double-diaphragm actuation. The double-diaphragm design eliminates the need for springs, o-rings and lubrication. Flow paths in the valve are arranged so that internal moving parts never contact the sample fl ow. As a result, abrasive mechanical wear on machined valve surfaces is eliminated. The valves are rated for over 5 million operations before repair (approximately 3-5 years of usage). And then, repair is typically simply changing the diaphragms in the valve. For many part-per-million applications, a simple easyto-maintain TCD detector can be used rather than a more complicated FID or FPD due to the superior sensitivity of the Rosemount Analytical TCD design. Most importantly, the Rosemount Analytical valve offers excellent performance. Minimal internal movement of the components in the valve - roughly 1/1000th of an inch - contributes to rapid actuation of the valve, which can be important for applications using micro-packed and capillary columns. The diaphragm valve used in the Model 1000 is so reliable, it comes with a lifetime warranty Detectors The Model 1000 Process Gas Chromatograph has the selection of detectors to handle the wide range of analytical demands found in typical process applications. Whether the components of interest are in the percent range or down to the parts-per-million range, precise and reliable measurement is possible. The Thermal Conductivity Detector (TCD) is the detector of choice for most applications due to its universal response to all compounds. The thermistor TCD from Emerson Process Management is also able to go well beyond the normal measuring ranges seen in other designs by being able to do many applications with low parts-per-million measurement requirements. This greatly simplifi es the process gas chromatograph design when a simple and rugged TCD can be used. For measurement of compounds in the low ppm or even ppb ranges, the Flame Ionization Detector (FID) for most organic compounds and the Flame Photometric Detector (FPD) for sulfur compounds are analytical options. Maintenance features such as auto-detection of fl ame loss are also standard. For maximum application fl exibility, the Model 1000 can have up to two detectors. Detector combinations like TCD-TCD, TCD-FID or TCD-FPD are well within the capability of the Model 1000. Page 2
Air Bath Oven The air bath oven uses a conventional instrument air heater design for maximum analytical fl exibility. The oven on the Model 1000 has capacity for up to 6 diaphragm chromatographs valves. There is also the capacity to install liquid injection sample valves for heavier samples. The oven can operate at temperatures up to 150 C (300 F) as the application dictates. Columns Since 1980, Emerson Process Management has been refi ning and improving its process for creating micropacked columns. Rosemount Analytical micro-packed columns offer a superior combination of the features found in both capillary and conventional packed columns. The result is improved chromatography with extended column life (several years in most applications without measurable degradation or bleed). Rosemount Analytical micro-packed columns produce sharper peaks for improved component separation, short analysis time and very low carrier-gas consumption. The air bath oven design of the Model 1000 Process Gas Chromatograph offers maximum analytical flexibility while maintaining easy access to all analytical components. The Design Makes The Difference: Built tough to stand up against any environment Tested tough to insure performance Field-mountable technology means solid performance at reduced cost Valves built so well, they re guaranteed for life! Detector options that meet your requirements Micro-packed columns that are made to last Page 3
MON2000 Software The Model 700 Process Gas Chromatograph is designed to operate unattended. If however, adjustments are needed; our exclusive MON2000 software allows complete control of your gas chromatographs - either locally or remotely. From within MON2000, a user can: Review and modify analytical settings Upload and display multiple chromatograms on the screen for comparison Upload and trend any of the measured results Export data for use in other 3rd party applications Overlay multiple chromatograms for troubleshooting and calibration Check original calibration against last calibration The MON2000 Software is Windows -based software designed to make analyzer confi guration, maintenance and data collection easy. With intuitive drop-down menus and fi ll-in-the-blank tables, even new users can quickly navigate through the software. The MON2000 software can display both current and multiple archived chromatograms on the screen streamlining the time needed to perform routine analyzer maintenance. MON2000 also has a number of tools built in that help users manage their analyzers such as: Automatic recording of alarms in a log fi le Event logs that provide a continuous record of all operator changes with time and user name stored Maintenance log scratch pad for keeping track of maintenance or testing done Data collected from the process gas chromatographs can be stored and displayed with a wide range of options such as trend lines on the screen and logs automatically documenting all changes made to the process gas chromatograph. Data can also be exported in formats compatible with most third-party Windows applications. Comparing multiple chromatograms and zooming into specific sections is easy with the point and click design of MON2000. Windows is a registered trademark of Microsoft Corporation Simple dropdown menus Connect to any GC with a mouse click Powerful Yet Simple MON2000 Software Summary of application event status and time Automatic listing of measured components Full featured chromatogram display Quickly add chromatograms to overlay Save CGM's to hard drive Page 4
Analyzer Networking and Data Communication Emerson s Rosemount Analytical Process Gas Chromatographs can be confi gured in a number of networking and data communication schemes to meet process communication requirements. Options include Ethernet networks as well as multi-drop RS-485 networks. It is even possible to set up automatic polling for data collection over phone lines if desired. Data communication options to the plant control system include simple analog and discrete signals as well as Modbus serial links. To preserve the integrity of the analysis data, all Model 1000 Process Gas Chromatographs are capable of storing up to 99 days of analysis data in the event of loss of communication to the plant control system. All Rosemount Analytical Process Gas Chromatographs are designed to operate unattended. Occasionally, adjustments to the analyzers analytical method or a review of alarms may be needed. Using our exclusive MON2000 software loaded on either a PC or laptop running Windows, you ll have complete control of your Process Gas Chromatographs either locally or remotely. Networking Flexibility Whether you want to network process gas chromatographs throughout the plant or simply link a single process gas chromatograph to the DCS system, the Model 1000 can be confi gured to handle most any scenario: Choice of Ethernet or RS-485 networks Can use the same network to connect Model 700, Model 500 and Model 1000 Process Gas Chromatographs Able to connect multiple PC workstations using MON2000 Connectivity to plant control systems using industry standard protocols such as Modbus and OPC Secure Modbus Connectivity For process gas chromatographs, Modbus continues to be the preferred choice to connect a process gas chromatograph network to the plant control system. Modbus design avoids the use of central interface cards or computers that can act as a single-point of failure in the Modbus link. Instead, the plant DCS system can talk directly to each process gas chromatograph to gather the data needed. Furthermore, the register and coil addresses can be easy customized to meet the specifi c data structure of the DCS. There is also a program built into the MON2000 workstation to test the Modbus link to the DCS if troubleshooting is needed. The Model 1000 Process Gas Chromatograph can either have the 2350A controller built into the face of the analyzer (shown) or mounted remotely in a 19" rack enclosure. With Ethernet, analyzers transmit directly to the plant s digital control system (including DeltaV ) quickly and securely using either industry standard Modbus or the new OPC protocol. Page 5
Custom Engineered Sample Systems Any process gas chromatograph is only as good as the quality of the sample it measures. So every sample system for Rosemount Analytical Process Gas Chromatographs is custom engineered for the specifi c requirements of the application. Common features include: Heated and open panel designs All components rated for the area classifi cation Automatic calibration / validation available as an option Variety of sample probes to extract a reliable and stable sample from the process Custom Engineered Process Analytical Systems A complete on-line analytical solution is more than just the analyzer. Sample conditioning systems to prepare the sample for analysis, communication links to the plant control computer, and packaging of the analytical equipment into a cabinet or shelter all play an important role. Emerson Process Management has decades of experience providing complete turnkey solutions ranging from simple single-analyzer cabinets up to large integrated shelters with multiple types of analyzers. The key to successful system integration begins at the proposal stage where Emerson Process Management develops a custom engineered solution. This is followed by experienced project management during the system fabrication and on to installation and training once the system is delivered to the fi eld. PUT EMERSON PROCESS MANAGEMENT'S EXPERIENCE TO WORK FOR YOU As one of the largest instrumentation and control system suppliers in the world. Emerson Process Management has the expertise and resources to tackle nearly any analytical system integration project. Whether the project is a simple 3-sided shelter or a large shelter with multiple types of analyzers, complete turnkey solutions are custom engineered to exactly match the needs of the customer. Page 6
Request A Quotation Every Model 1000 Process Gas Chromatograph is custom built for the specifi c application requested. To request a free quotation, simply fi ll out the information below and send it to the address at the end of this Data Sheet. You can also fi nd an electronic version of the Request For Quotation form at our web site http://www.raihome.com Name: Title: Company: Address: Your Reference #: Project Name: Process Unit: Stream Name(s): Phone #: Fax #: Email: Hazardous Area Classification: Stream Composition Units Stream 1 Stream 2 Min Normal Max Measure Min Normal Max Measure (For more than two streams, make copies of this page) Stream Temperature: Stream Pressure: Stream Phase (vapor / liquid) Stream Contaminants: Stream 1 Stream 2 Distance to GC from Sample Point: Controller: Integral ( ) 19" Rack-Mount ( ) Power: 110 VAC ( ) 220 VAC ( ) Data Communication: Analog Output ( ) Modbus ( ) OPC ( ) Printer ( ) Modem ( ) Analyzer Network: Ethernet ( ) RS-485 Multi-Drop ( ) Other Options: Carrier Gas ( ) Calibration Gas ( ) Start-Up ( ) Training Class ( ) Special Instructions: Page 7
MODEL 1000 SPECIFICATIONS Power: 115 VAC ±15%, 220 VAC ±15%, 50/60 HZ 400 watts running, 1100 watts start-up Environment: 0 to 55 C (32 to 130 F) for TCD and FID; 20 C ± 5 C (70 F ± 10 F) for FPD Dimensions (without sample system): 198 cm H x 61cm W x 61cm D (78" H x 24" W x 24" D) Mounting: wall-mount (standard); free-standing (optional) Approximate Weight (without sample system): approximately 68 kg. (150 lbs.) Area Classification Options (hardware dependant): designed to meet Class 1, Div. I, Groups B, C, D with X-Purge; Class 1 Div. 2, Groups B, C, D with Z-Purge, ATEX certifi ed EExpII T3 (optional) Instrument Air: 4 SCFM at 40 psig of oil-free instrument air for purge and oven heat and 90 psig for valve actuation Oven: air bath oven, maximum 150 C (300 F) Valves: 6-port and 10-port diaphragm chromatograph valves (maximum 6 valves). Other types of valves may be used depending on the application such as liquid injection and rotary valves Carrier Gas: application-dependent. Typically zero-grade helium, nitrogen or hydrogen at 90 psig Columns: choice of packed, micro-packed or capillary columns; application-dependent Detector: Thermal Conductivity Detector (TCD), Flame Ionization Detector (FID) or Flame Photometric Detector (FPD); TCD-TCD, TCD-FID or TCD-FPD dual detector combinations possible Gating Options: fi xed-time, slope and automatic gating of peaks Streams: up to 12 streams Chromatograph Control Electronics: integrally mounted Analog Inputs: four inputs fi ltered with transient protection (note that the 4 inputs will be used by the second detector if present) Analog Outputs: two standard (up to 10 optional), 4 20 ma, non-isolated Serial Communication Ports: three serial ports standard with option for a total of eight. Depending on the port, choice of RS-232, RS-422 and RS-485 is available as well as the Modbus protocol Digital Inputs (optional): one gas chromatograph alarm and fi ve user assignable inputs, optically isolated with transient protection Digital Outputs (optional): fi ve digital outputs can be used for alarms, optically isolated with transient protection Parallel Printer Port (optional): one parallel port available for printed reports Internal Modem (optional): fi eld-confi gurable; 300 to 19.2k baud 67.0 INSTRUMENT AIR IN 1/4 ELECTRONICS ENCLOSURE 75.5 ANALYZER OVEN S.C.S. OVEN 9.00 0.00 24.00 24.00 36.00 Model 1000 Dimensional Drawing The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifi cations of our products at any time without notice. Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 5650 Brittmoore Road Houston, TX 77041 USA T: 713.827.6380, F: 713.827.3865 Toll Free in US and Canada: 1.866.GC.CENTER Email: gc.csc@emersonprocess.com www.raihome.com Rosemount Analytical Inc., 2005. All rights reserved. Printed in U.S.A. on recycled paper.